US20020189599A1 - Diagnosis system for upstream gauge sensor, downstream absolute pressure sensor - Google Patents
Diagnosis system for upstream gauge sensor, downstream absolute pressure sensor Download PDFInfo
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- US20020189599A1 US20020189599A1 US09/681,860 US68186001A US2002189599A1 US 20020189599 A1 US20020189599 A1 US 20020189599A1 US 68186001 A US68186001 A US 68186001A US 2002189599 A1 US2002189599 A1 US 2002189599A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L19/00—Details of, or accessories for, apparatus for measuring steady or quasi-steady pressure of a fluent medium insofar as such details or accessories are not special to particular types of pressure gauges
- G01L19/14—Housings
- G01L19/147—Details about the mounting of the sensor to support or covering means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/0025—Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
- F02D41/0047—Controlling exhaust gas recirculation [EGR]
- F02D41/0065—Specific aspects of external EGR control
- F02D41/0072—Estimating, calculating or determining the EGR rate, amount or flow
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/02—Circuit arrangements for generating control signals
- F02D41/04—Introducing corrections for particular operating conditions
- F02D41/047—Taking into account fuel evaporation or wall wetting
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/02—Circuit arrangements for generating control signals
- F02D41/14—Introducing closed-loop corrections
- F02D41/1438—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor
- F02D41/1444—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases
- F02D41/1448—Introducing closed-loop corrections using means for determining characteristics of the combustion gases; Sensors therefor characterised by the characteristics of the combustion gases the characteristics being an exhaust gas pressure
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/22—Safety or indicating devices for abnormal conditions
- F02D41/222—Safety or indicating devices for abnormal conditions relating to the failure of sensors or parameter detection devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/45—Sensors specially adapted for EGR systems
- F02M26/46—Sensors specially adapted for EGR systems for determining the characteristics of gases, e.g. composition
- F02M26/47—Sensors specially adapted for EGR systems for determining the characteristics of gases, e.g. composition the characteristics being temperatures, pressures or flow rates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/49—Detecting, diagnosing or indicating an abnormal function of the EGR system
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D2200/00—Input parameters for engine control
- F02D2200/02—Input parameters for engine control the parameters being related to the engine
- F02D2200/04—Engine intake system parameters
- F02D2200/0402—Engine intake system parameters the parameter being determined by using a model of the engine intake or its components
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D2200/00—Input parameters for engine control
- F02D2200/02—Input parameters for engine control the parameters being related to the engine
- F02D2200/04—Engine intake system parameters
- F02D2200/0406—Intake manifold pressure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/02—Bonding areas; Manufacturing methods related thereto
- H01L2224/04—Structure, shape, material or disposition of the bonding areas prior to the connecting process
- H01L2224/05—Structure, shape, material or disposition of the bonding areas prior to the connecting process of an individual bonding area
- H01L2224/0554—External layer
- H01L2224/05599—Material
- H01L2224/056—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron [B], silicon [Si], germanium [Ge], arsenic [As], antimony [Sb], tellurium [Te] and polonium [Po], and alloys thereof
- H01L2224/05617—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron [B], silicon [Si], germanium [Ge], arsenic [As], antimony [Sb], tellurium [Te] and polonium [Po], and alloys thereof the principal constituent melting at a temperature of greater than or equal to 400°C and less than 950°C
- H01L2224/05624—Aluminium [Al] as principal constituent
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
- H01L2224/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
- H01L2224/45001—Core members of the connector
- H01L2224/45099—Material
- H01L2224/451—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof
- H01L2224/45138—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof the principal constituent melting at a temperature of greater than or equal to 950°C and less than 1550°C
- H01L2224/45144—Gold (Au) as principal constituent
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/40—Engine management systems
Definitions
- the field of the invention relates to engine systems using pressure sensors.
- the field of the invention relates to systems that use a determination of barometric pressure.
- Engine systems which utilize exhaust gas recirculation (EGR) to reduce engine emission and increase fuel economy.
- EGR exhaust gas recirculation
- two pressure sensors are utilized not only to calculate EGR flow into the engine, but also to control air-fuel ratio.
- one sensor is coupled to the intake manifold and another is coupled in the EGR pathway between an EGR valve and an orifice.
- EGR exhaust gas recirculation
- the inventors herein have recognized that there is a potential that the pressure sensors in such a system may degrade.
- the intake manifold pressure sensor degrades, engine air-fuel ratio control may degrade thus affecting emissions.
- the pressure sensor coupled to the EGR system degrades, EGR flow control and flow estimation may degrade.
- a method for controlling an engine coupled to an exhaust gas recirculation system the engine coupled to a first pressure sensor and the exhaust gas recirculation system coupled to second pressure sensor.
- the method comprises determining whether at least one of the first and second pressure sensor has degraded, and in response to said determination, discontinuing exhaust gas recirculation and calculating an engine air intake amount based on the other of said indicated at least one pressure sensor.
- An advantage of the invention is improved engine control during sensor degradation.
- Another advantage of the invention is that engine operation can be continued even when sensor degradation occurs.
- FIG. 1 is a block diagram of an engine in which the invention is used to advantage
- FIG. 2 is a schematic diagram of the EGR system
- FIGS. 3 - 6 are a high level flowcharts of various routines for controlling EGR flow.
- FIGS. 7 - 8 are schematic diagrams of pressure sensors.
- Internal combustion engine 10 comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1, is controlled by electronic engine controller 12 .
- Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 .
- Combustion chamber 30 communicates with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 .
- Exhaust gas oxygen sensor 16 is coupled to exhaust manifold 48 of engine 10 upstream of catalytic converter 20 .
- Intake manifold 44 communicates with throttle body 64 via throttle plate 66 .
- Intake manifold 44 is also shown having fuel injector 68 coupled thereto for delivering fuel in proportion to the pulse width of signal (fpw) from controller 12 .
- Fuel is delivered to fuel injector 68 by a conventional fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown).
- Engine 10 further includes conventional distributorless ignition system 88 to provide ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 .
- controller 12 is a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , electronic memory chip 106 , which is an electronically programmable memory in this particular example, random access memory 108 , and a conventional data bus.
- Controller 12 receives various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: measurements of inducted mass air flow (MAF) from mass air flow sensor 110 coupled to throttle body 64 ; engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling jacket 114 ; a measurement of manifold pressure (MAP) from manifold pressure sensor 116 coupled to intake manifold 44 ; a measurement of throttle position (TP) from throttle position sensor 117 coupled to throttle plate 66 ; and a profile ignition pickup signal (PIP) from Hall effect sensor 118 coupled to crankshaft 40 indicating and engine speed (N).
- MAF inducted mass air flow
- ECT engine coolant temperature
- MAP manifold pressure
- TP throttle position
- PIP profile ignition pickup signal
- Exhaust gas is delivered to intake manifold 44 by a conventional EGR tube 202 communicating with exhaust manifold 48 , EGR valve assembly 200 , and EGR orifice 205 .
- tube 202 could be an internally routed passage in the engine that communicates between exhaust manifold 48 and intake manifold 44 .
- Pressure sensor 206 communicates with EGR tube 202 between valve assembly 200 and orifice 205 .
- Pressure sensor 207 communicates with intake manifold 44 . Stated another way, exhaust gas travels from exhaust manifold 44 first through valve assembly 200 , then through EGR orifice 205 , to intake manifold 44 .
- EGR valve assembly 200 can then be said to be located upstream of orifice 205 .
- pressure sensor 206 can be either absolute pressure sensor 700 or a gauge pressure sensor 800 , which are described later herein in FIGS. 7 and 8.
- pressure sensor 207 can be either absolute pressure sensor 700 or a gauge pressure sensor 800 .
- pressure sensor 206 can be absolute pressure sensor 700
- pressure sensor 207 can be gauge pressure sensor 800 .
- Flow sensor 206 provides a measurement of manifold pressure (MAP) and pressure drop across orifice 205 (DP) to controller 12 . Signals MAP and DP are then used to calculated EGR flow as described later herein with particular reference to FIGS. 3 - 5 .
- EGR valve assembly 200 has a valve position (not shown) for controlling a variable area restriction in EGR tube 202 , which thereby controls EGR flow. EGR valve assembly 200 can either minimally restrict EGR flow through tube 202 or completely restrict EGR flow through tube 202 .
- Vacuum regulator 224 is coupled to EGR valve assembly 200 . Vacuum regulator 224 receives actuation signal ( 226 ) from controller 12 for controlling valve position of EGR valve assembly 200 .
- EGR valve assembly 200 is a vacuum actuated valve.
- any type of flow control valve may be used such as, for example, an electrical solenoid powered valve or a stepper motor powered valve.
- step 310 the most recent BP estimate (BPA) is read.
- BPA BP estimate
- step 312 the routine determines the absolute pressure upstream of orifice 205 .
- the absolute pressure upstream of orifice 205 is determined based on the sum of the most recent BP estimate and the measured gauge pressure upstream of orifice 205 . Further, this upstream absolute pressure is clipped to be at least greater than the absolute pressure measured by the absolute pressure sensor downstream of orifice 205 . Further, if it is necessary to clip the values, this indicates that the estimate of barometric pressure has degraded.
- the desired EGR flow is set to zero so that the barometric pressure can be updated as described later herein with particular reference to FIG. 4.
- step 314 the EGR flow is determined based on the upstream absolute pressure and downstream absolute pressure using function f.
- function f is structured so that EGR flow is calculated based on the square root of the product of downstream absolute pressure and differential pressure across orifice 205 .
- step 316 feedback EGR control is performed based on a desired EGR flow and the calculated EGR flow from step 314 .
- step 410 a determination is made as to whether the engine is stopped. This can be determined by, for example, determining whether the ignition key is on, whether engine rpm is zero, or whether engine speed is zero for a predetermined duration, or whether engine fuel injection is zero, or various other parameters that indicate that the engine is stopped.
- the routine continues to step 412 .
- step 412 the routine updates the BP estimate based on the measured absolute pressure downstream orifice 205 , which in this embodiment is also the manifold absolute pressure. In other words, when the engine is stopped, the routine determines absolute barometric pressure based on the measured manifold pressure, or pressure downstream of orifice 205 . Then, in step 414 , the old barometric pressure is set equal to the most recently updated barometric pressure.
- step 416 a determination is made as to whether the EGR flow is substantially equal to zero.
- determining whether EGR flow is equal to zero such as, for example, determining whether the EGR valve is closed, determining whether the duty cycle command to the EGR valve is zero, determining whether the pressure upstream of the orifice is approximately equal to pressure downstream of the orifice, or any other parameter that indicates that EGR flow is substantially equal to zero.
- the definition of “substantially” equal to zero is when the indication of flow based on the pressure sensors is equal to a value that would be caused by noise on the sensors during engine operation.
- the flow is substantially zero when the flow indicated is less than 10% of the maximum flow through the system during the present engine operating conditions.
- pressure upstream is approximately equal to pressure downstream of the orifice when, for example, the pressure values are within 10% of each other. However, this depends on the accuracy of the sensor and the amount of noise that is generated during the present engine operating conditions.
- the barometric pressure estimate is updated using a low pass filter in the equation in the Figure.
- the absolute pressure upstream of orifice 205 is substantially equal to the absolute pressure downstream of orifice 205 since there is no flow.
- the absolute pressure measurement of the downstream pressure can be used in conjunction with the gauge pressure measurement upstream of orifice 205 to determine the reference pressure to the gauge sensor.
- the reference pressure to the gauge pressure sensor which measures the gauge pressure upstream of orifice 205 , is atmospheric pressure.
- the barometric pressure estimate is not updated via the absolute pressure measurement downstream of orifice 205 but is set equal to the old BP estimate value.
- other estimates can be used at this time to provide an estimate of barometric pressure.
- the engine mass airflow sensor and throttle position can be used to estimate barometric pressure.
- a routine is described that can provide online estimates of atmospheric pressure during vehicle driving conditions when the EGR flow is equal to zero using an upstream gauge pressure sensor and a downstream absolute pressure sensor.
- step 510 a determination is made as to whether the gauge pressure sensor has degraded.
- the routine continues to step 512 .
- degradation can be determined based on a variety of methods. For example, sensor voltage can be compared to an allowable range. If sensor voltage is outside of the allowable range, degradation can be indicated. Further, an estimate of the sensor value can be obtained using other engine operating parameters and then compared with the sensor reading. If this comparison gives a difference that is greater than an allowable value, degradation is indicated.
- step 512 the routine discontinues EGR flow and controls fuel injection based on the absolute pressure measurement downstream of orifice 205 (manifold pressure).
- the routine calculates the fuel injection amount based on speed density equations that relate air induction amount to manifold pressure and engine speed and engine manifold temperature. In this way, it is possible to continue engine operation even when upstream gauge pressure sensor has degraded. Also, fuel injection can be further adjusted based on feedback from a signal from sensor 16 indicative of exhaust air-fuel ratio.
- step 514 a determination is made in step 514 as to whether downstream absolute pressure sensor has degraded.
- the routine continues to step 516 .
- sensor voltage can be compared to an allowable range. If sensor voltage is outside of the allowable range, degradation can be indicated. Further, an estimate of the sensor value can be obtained using other engine operating parameters and then compared with the sensor reading. If this comparison gives a difference that is greater than an allowable value, degradation is indicated.
- step 516 the routine discontinues EGR flow and controls fuel injection amount based on the gauge pressure sensor and the most recent barometric pressure estimate.
- the absolute pressure upstream of orifice 205 is approximately equal to the absolute pressure downstream of orifice 205 .
- this estimated manifold pressure can be used with the speed density functions to calculate a proper fuel injection amount.
- a routine is provided for default operation of an engine EGR system having two absolute pressure sensors, one upstream of orifice 205 and one downstream of orifice 205 .
- step 610 a determination is made as to whether either absolute pressure sensor is degraded.
- the routine discontinues EGR and controls fuel injection amount based on the absolute pressure sensor that has not degraded. In other words, when EGR flow is zero, both absolute pressure sensors should be reading approximately the same absolute pressure. Thus, the routine uses whichever sensor has not degraded to provide the fuel injection control.
- the present invention can be utilized with a hybrid electric vehicle system.
- an engine and an electric motor are coupled to the vehicle.
- both the engine and the electric motor drive the vehicle.
- only the engine or only the electric motor drive the vehicle.
- the engine drives the electric motor to recharge a battery system.
- estimates of barometric pressure can be obtained while the vehicle is operating under the pure electric mode and the engine is stopped.
- Absolute pressure sensor 700 which is coupled to engine intake manifold 44 , is described.
- Absolute pressure sensor 700 comprises a base structure 705 , which supports the pressure sensor elements as described below. Coupled to base 705 is support member 710 .
- Support member 710 is comprised of silicon.
- Support member 710 has a sealed vacuum reference chamber 720 within. Vacuum reference chamber serves as a regulated reference pressure so that sensor 700 can provide an indication of absolute pressure sensor regulated reference pressure is known and fixed.
- Coupled to support 710 are aluminum conductors and an electronics layer 730 .
- This aluminum conductor and electronics layer 730 contains sensitive electronic components that convert the applied pressure and the vacuum reference into electrical signals provided to controller 12 .
- a nitride layer 740 is coupled on top of aluminum conductor and electronics layer 730 .
- gold wire bonds 780 connect the aluminum conductor and electronics layer 730 to base 705 .
- a gel layer 760 surrounds the aluminum conductor and electronics layer 730 , nitride layer 740 , support 710 , vacuum reference 720 , and gold wire bonds 780 . The pressure to be measured is applied to gel layer 760 .
- Gel layer 760 protects the sensitive electronics in layer 730 from the gases creating the applied pressure.
- gauge pressure sensor 800 is described.
- gauge pressure sensor 800 is measured relative to atmospheric pressure.
- Base 800 is shown coupled to support 810 .
- Support 810 is comprised of silicon.
- Aluminum conductors and electronics layer 830 is coupled to one side of support 810 .
- the opposite side of support 810 is constructed so that the measured, or applied, pressure is in contact with support 810 .
- aluminum conductors and electronics layer 830 comprise sensitive electronic components.
- Nitride layer 840 is coupled to aluminum conductors and electronics layer 830 .
- diaphragm 850 is coupled within nitride layer 840 and coupled to aluminum electronics layer 830 . Atmospheric pressure is applied to diaphragm 850 and nitride layer 840 .
- Gold wire bonds 880 couple aluminum electronics layer 830 to base 800 .
- gauge pressure sensor 800 does not suffer from the disadvantages suffered by absolute sensor 700 with respect to the requirements for gel layer 760 . In other words, with gauge pressure sensor 800 , it is possible to measure exhaust pressure as the applied pressure, without adding expensive gels to protect the sensitive electronics in the layer 830 .
- gauge pressure sensor 800 can be manufactured cheaply and provide useful measurements of recycled exhaust gases.
- the improved barometric pressure estimate can be used in other engine control systems.
- the improved barometric pressure estimate can be used in scheduling engine actuators and desired engine operating points.
- the improved barometric pressure estimate can be used in determining a desired EGR flow, or EGR valve, set-point.
- the measured, or estimated EGR flow value can be used in a feedback control scheme so that the actual EGR flow, or valve position, approaches the set-point value.
- the improved barometric pressure estimate can be used in determining a ignition timing set-point. In other words, desired ignition timing can be varied based on the determined barometric pressure.
Abstract
Description
- 1. Technical Field
- The field of the invention relates to engine systems using pressure sensors. In particular, the field of the invention relates to systems that use a determination of barometric pressure.
- 2. Background of the Invention
- Engine systems are known which utilize exhaust gas recirculation (EGR) to reduce engine emission and increase fuel economy. In one example, two pressure sensors are utilized not only to calculate EGR flow into the engine, but also to control air-fuel ratio. Typically, one sensor is coupled to the intake manifold and another is coupled in the EGR pathway between an EGR valve and an orifice. Such a system that provides dual use of sensors can offer cost advantages. Such a system is described in U.S. Pat. No. 6,138,504.
- The inventors herein have recognized that there is a potential that the pressure sensors in such a system may degrade. In particular, if the intake manifold pressure sensor degrades, engine air-fuel ratio control may degrade thus affecting emissions. Further, if the pressure sensor coupled to the EGR system degrades, EGR flow control and flow estimation may degrade.
- In one example, the above advantages over prior approaches are provided by a method for controlling an engine coupled to an exhaust gas recirculation system, the engine coupled to a first pressure sensor and the exhaust gas recirculation system coupled to second pressure sensor. The method comprises determining whether at least one of the first and second pressure sensor has degraded, and in response to said determination, discontinuing exhaust gas recirculation and calculating an engine air intake amount based on the other of said indicated at least one pressure sensor.
- By utilizing the remaining operational pressure sensor when one pressure sensor has degraded, it is possible to accurately determine air entering the engine and therefore accurately control engine air-fuel ratio. This is particularly true since EGR has been discontinued. For example, the amount of EGR flowing into the engine affects the amount of fresh air inducted for a given manifold pressure. Thus, by discontinuing EGR, this error source is removed and accurate air determination is possible even with a reduced sensor set.
- An advantage of the invention is improved engine control during sensor degradation.
- Another advantage of the invention is that engine operation can be continued even when sensor degradation occurs.
- The advantages described herein will be more fully understood by reading an example of an embodiment in which the invention is used to advantage, referred to herein as the Description of the Preferred Embodiment, with reference to the drawings wherein:
- FIG. 1 is a block diagram of an engine in which the invention is used to advantage;
- FIG. 2 is a schematic diagram of the EGR system;
- FIGS.3-6 are a high level flowcharts of various routines for controlling EGR flow; and
- FIGS.7-8 are schematic diagrams of pressure sensors.
-
Internal combustion engine 10, comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1, is controlled byelectronic engine controller 12.Engine 10 includescombustion chamber 30 andcylinder walls 32 withpiston 36 positioned therein and connected tocrankshaft 40.Combustion chamber 30 communicates withintake manifold 44 andexhaust manifold 48 viarespective intake valve 52 andexhaust valve 54. Exhaustgas oxygen sensor 16 is coupled toexhaust manifold 48 ofengine 10 upstream ofcatalytic converter 20. -
Intake manifold 44 communicates withthrottle body 64 viathrottle plate 66.Intake manifold 44 is also shown havingfuel injector 68 coupled thereto for delivering fuel in proportion to the pulse width of signal (fpw) fromcontroller 12. Fuel is delivered tofuel injector 68 by a conventional fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown).Engine 10 further includes conventionaldistributorless ignition system 88 to provide ignition spark tocombustion chamber 30 viaspark plug 92 in response tocontroller 12. In the embodiment described herein,controller 12 is a conventional microcomputer including:microprocessor unit 102, input/output ports 104,electronic memory chip 106, which is an electronically programmable memory in this particular example,random access memory 108, and a conventional data bus. -
Controller 12 receives various signals from sensors coupled toengine 10, in addition to those signals previously discussed, including: measurements of inducted mass air flow (MAF) from massair flow sensor 110 coupled tothrottle body 64; engine coolant temperature (ECT) fromtemperature sensor 112 coupled tocooling jacket 114; a measurement of manifold pressure (MAP) from manifold pressure sensor 116 coupled tointake manifold 44; a measurement of throttle position (TP) fromthrottle position sensor 117 coupled tothrottle plate 66; and a profile ignition pickup signal (PIP) fromHall effect sensor 118 coupled tocrankshaft 40 indicating and engine speed (N). - Exhaust gas is delivered to intake
manifold 44 by aconventional EGR tube 202 communicating withexhaust manifold 48,EGR valve assembly 200, and EGRorifice 205. Alternatively,tube 202 could be an internally routed passage in the engine that communicates betweenexhaust manifold 48 andintake manifold 44.Pressure sensor 206 communicates with EGRtube 202 betweenvalve assembly 200 andorifice 205. Pressure sensor 207 communicates withintake manifold 44. Stated another way, exhaust gas travels fromexhaust manifold 44 first throughvalve assembly 200, then through EGRorifice 205, to intakemanifold 44.EGR valve assembly 200 can then be said to be located upstream oforifice 205. Also,pressure sensor 206 can be eitherabsolute pressure sensor 700 or agauge pressure sensor 800, which are described later herein in FIGS. 7 and 8. Further, pressure sensor 207 can be eitherabsolute pressure sensor 700 or agauge pressure sensor 800. Further yet,pressure sensor 206 can beabsolute pressure sensor 700, while pressure sensor 207 can begauge pressure sensor 800. -
Flow sensor 206 provides a measurement of manifold pressure (MAP) and pressure drop across orifice 205 (DP) to controller 12. Signals MAP and DP are then used to calculated EGR flow as described later herein with particular reference to FIGS. 3-5.EGR valve assembly 200 has a valve position (not shown) for controlling a variable area restriction inEGR tube 202, which thereby controls EGR flow.EGR valve assembly 200 can either minimally restrict EGR flow throughtube 202 or completely restrict EGR flow throughtube 202.Vacuum regulator 224 is coupled toEGR valve assembly 200.Vacuum regulator 224 receives actuation signal (226) fromcontroller 12 for controlling valve position ofEGR valve assembly 200. In a preferred embodiment,EGR valve assembly 200 is a vacuum actuated valve. However, as is obvious to those skilled in the art, any type of flow control valve may be used such as, for example, an electrical solenoid powered valve or a stepper motor powered valve. - Referring now to FIG. 3, a routine is described for feedback controlling exhaust gas recirculation according to the present invention.
- First, in
step 310, the most recent BP estimate (BPA) is read. The routine for updating the BP estimate is described later herein with particular reference to FIG. 4. - Next, in
step 312, the routine determines the absolute pressure upstream oforifice 205. In particular, the absolute pressure upstream oforifice 205 is determined based on the sum of the most recent BP estimate and the measured gauge pressure upstream oforifice 205. Further, this upstream absolute pressure is clipped to be at least greater than the absolute pressure measured by the absolute pressure sensor downstream oforifice 205. Further, if it is necessary to clip the values, this indicates that the estimate of barometric pressure has degraded. Thus, according to the present invention, when this clipping occurs, the desired EGR flow is set to zero so that the barometric pressure can be updated as described later herein with particular reference to FIG. 4. - Next, in
step 314, the EGR flow is determined based on the upstream absolute pressure and downstream absolute pressure using function f. In one aspect of the present invention, function f is structured so that EGR flow is calculated based on the square root of the product of downstream absolute pressure and differential pressure acrossorifice 205. Then, in step 316, feedback EGR control is performed based on a desired EGR flow and the calculated EGR flow fromstep 314. - Referring now to FIG. 4, a routine is described for estimating atmospheric pressure, or barometric pressure, during vehicle operation.
- First, in
step 410, a determination is made as to whether the engine is stopped. This can be determined by, for example, determining whether the ignition key is on, whether engine rpm is zero, or whether engine speed is zero for a predetermined duration, or whether engine fuel injection is zero, or various other parameters that indicate that the engine is stopped. When the answer to step 410 is yes, the routine continues to step 412. Instep 412, the routine updates the BP estimate based on the measured absolute pressuredownstream orifice 205, which in this embodiment is also the manifold absolute pressure. In other words, when the engine is stopped, the routine determines absolute barometric pressure based on the measured manifold pressure, or pressure downstream oforifice 205. Then, instep 414, the old barometric pressure is set equal to the most recently updated barometric pressure. - When the answer to step410 is no, the routine continues to step 416, where a determination is made as to whether the EGR flow is substantially equal to zero. There are various methods for determining whether EGR flow is equal to zero such as, for example, determining whether the EGR valve is closed, determining whether the duty cycle command to the EGR valve is zero, determining whether the pressure upstream of the orifice is approximately equal to pressure downstream of the orifice, or any other parameter that indicates that EGR flow is substantially equal to zero. Further, the definition of “substantially” equal to zero is when the indication of flow based on the pressure sensors is equal to a value that would be caused by noise on the sensors during engine operation. For example, the flow is substantially zero when the flow indicated is less than 10% of the maximum flow through the system during the present engine operating conditions. Also, pressure upstream is approximately equal to pressure downstream of the orifice when, for example, the pressure values are within 10% of each other. However, this depends on the accuracy of the sensor and the amount of noise that is generated during the present engine operating conditions. When the answer to step 416 is yes, the routine continues to step 418.
- In
step 418, the barometric pressure estimate is updated using a low pass filter in the equation in the Figure. In other words, when the EGR flow is zero, the absolute pressure upstream oforifice 205 is substantially equal to the absolute pressure downstream oforifice 205 since there is no flow. Thus, the absolute pressure measurement of the downstream pressure can be used in conjunction with the gauge pressure measurement upstream oforifice 205 to determine the reference pressure to the gauge sensor. In this example, the reference pressure to the gauge pressure sensor, which measures the gauge pressure upstream oforifice 205, is atmospheric pressure. Thus, according to the present invention, when EGR flow is zero, it is possible to accurately measure the atmospheric pressure using both the gauge and absolute pressure sensors coupled upstream and downstream oforifice 205. - When the answer to step416 is no, the barometric pressure estimate is not updated via the absolute pressure measurement downstream of
orifice 205 but is set equal to the old BP estimate value. However, in an alternative embodiment, other estimates can be used at this time to provide an estimate of barometric pressure. For example, the engine mass airflow sensor and throttle position can be used to estimate barometric pressure. Thus, according to the present invention, a routine is described that can provide online estimates of atmospheric pressure during vehicle driving conditions when the EGR flow is equal to zero using an upstream gauge pressure sensor and a downstream absolute pressure sensor. - Referring now to FIG. 5, a routine is described for default operation of an engine EGR system having an upstream gauge pressure sensor and a downstream absolute pressure sensor.
- First, in step510 a determination is made as to whether the gauge pressure sensor has degraded. When the answer to step 510 is yes, the routine continues to step 512. In particular, degradation can be determined based on a variety of methods. For example, sensor voltage can be compared to an allowable range. If sensor voltage is outside of the allowable range, degradation can be indicated. Further, an estimate of the sensor value can be obtained using other engine operating parameters and then compared with the sensor reading. If this comparison gives a difference that is greater than an allowable value, degradation is indicated.
- In
step 512, the routine discontinues EGR flow and controls fuel injection based on the absolute pressure measurement downstream of orifice 205 (manifold pressure). In other words, the routine calculates the fuel injection amount based on speed density equations that relate air induction amount to manifold pressure and engine speed and engine manifold temperature. In this way, it is possible to continue engine operation even when upstream gauge pressure sensor has degraded. Also, fuel injection can be further adjusted based on feedback from a signal fromsensor 16 indicative of exhaust air-fuel ratio. - When the answer to step510 is no, a determination is made in step 514 as to whether downstream absolute pressure sensor has degraded. When the answer to step 514 is yes, the routine continues to step 516. For example, sensor voltage can be compared to an allowable range. If sensor voltage is outside of the allowable range, degradation can be indicated. Further, an estimate of the sensor value can be obtained using other engine operating parameters and then compared with the sensor reading. If this comparison gives a difference that is greater than an allowable value, degradation is indicated.
- In
step 516, the routine discontinues EGR flow and controls fuel injection amount based on the gauge pressure sensor and the most recent barometric pressure estimate. In other words, when EGR flow is zero, the absolute pressure upstream oforifice 205 is approximately equal to the absolute pressure downstream oforifice 205. Thus, by using the gauge pressure upstream oforifice 205 and the most recent estimate of barometric pressure, it is possible to estimate an absolute pressure downstream of orifice 205 (estimated intake manifold pressure). Then, this estimated manifold pressure can be used with the speed density functions to calculate a proper fuel injection amount. Thus, according to the present invention, it is possible to continue accurate engine operation of a system having an upstream gauge pressure sensor and a downstream absolute pressure sensor, when the downstream absolute pressure sensor has degraded. - Referring now to FIG. 6, a routine is provided for default operation of an engine EGR system having two absolute pressure sensors, one upstream of
orifice 205 and one downstream oforifice 205. - First, in
step 610, a determination is made as to whether either absolute pressure sensor is degraded. When the answer to step 610 is yes, the routine discontinues EGR and controls fuel injection amount based on the absolute pressure sensor that has not degraded. In other words, when EGR flow is zero, both absolute pressure sensors should be reading approximately the same absolute pressure. Thus, the routine uses whichever sensor has not degraded to provide the fuel injection control. - While various methods can be used to determine whether a pressure sensor has degraded, one potential method is to determine whether the voltage output is within acceptable predetermined voltage limits. Thus, if the voltage read by the sensor is outside of this acceptable output range, degradation can be indicated. However, there are various other methods for determining degradation such as using other engine operating parameters to estimate the pressure, and indicating degradation when these values disagree by a predetermined amount.
- In an alternative embodiment, the present invention can be utilized with a hybrid electric vehicle system. In this system, an engine and an electric motor are coupled to the vehicle. In some operating modes, both the engine and the electric motor drive the vehicle. In other operating modes, only the engine or only the electric motor drive the vehicle. In still other operating modes, the engine drives the electric motor to recharge a battery system. According to the present invention, it is possible to update a barometric pressure estimate when the vehicle is driven by the electric motor and the engine is stopped (see
step 410 of FIG. 4). In other words, estimates of barometric pressure can be obtained while the vehicle is operating under the pure electric mode and the engine is stopped. Thus, it is possible to provide continuing updates in barometric pressure using a manifold absolute pressure sensor. - Referring now to FIG. 7, a schematic diagram of an absolute pressure sensor is described. In particular,
absolute pressure sensor 700, which is coupled toengine intake manifold 44, is described.Absolute pressure sensor 700 comprises abase structure 705, which supports the pressure sensor elements as described below. Coupled tobase 705 issupport member 710.Support member 710 is comprised of silicon.Support member 710 has a sealedvacuum reference chamber 720 within. Vacuum reference chamber serves as a regulated reference pressure so thatsensor 700 can provide an indication of absolute pressure sensor regulated reference pressure is known and fixed. Coupled to support 710 are aluminum conductors and anelectronics layer 730. This aluminum conductor andelectronics layer 730 contains sensitive electronic components that convert the applied pressure and the vacuum reference into electrical signals provided tocontroller 12. Anitride layer 740 is coupled on top of aluminum conductor andelectronics layer 730. Also,gold wire bonds 780 connect the aluminum conductor andelectronics layer 730 tobase 705. Agel layer 760 surrounds the aluminum conductor andelectronics layer 730,nitride layer 740,support 710,vacuum reference 720, and gold wire bonds 780. The pressure to be measured is applied togel layer 760.Gel layer 760 protects the sensitive electronics inlayer 730 from the gases creating the applied pressure. - The inventors herein have recognized that while it is possible to manufacture a gel layer, which can protect the electronics from hot exhaust gases containing various contaminants, this can be an expensive approach. Thus, according to the present invention, absolute sensor is used to measure intake manifold pressure, which is comprised primarily of fresh air inducted
past throttle plate 66 from the atmosphere. Thus, a relativelyinexpensive gel layer 760 can be utilized and exploited. Thus, while it is possible to use an absolute sensor such as described above to measure exhaust pressures, it is also desirable to provide alternative methods and systems that do not rely solely on absolute pressure sensors. - Referring now to FIG. 8,
gauge pressure sensor 800 is described. In this particular embodiment,gauge pressure sensor 800 is measured relative to atmospheric pressure. However, various other reference pressures may be used.Base 800 is shown coupled to support 810. Support 810 is comprised of silicon. Aluminum conductors andelectronics layer 830 is coupled to one side of support 810. The opposite side of support 810 is constructed so that the measured, or applied, pressure is in contact with support 810. - As above, aluminum conductors and
electronics layer 830 comprise sensitive electronic components.Nitride layer 840 is coupled to aluminum conductors andelectronics layer 830. Also,diaphragm 850 is coupled withinnitride layer 840 and coupled toaluminum electronics layer 830. Atmospheric pressure is applied todiaphragm 850 andnitride layer 840.Gold wire bonds 880 couplealuminum electronics layer 830 tobase 800. - The inventors herein have recognized that
gauge pressure sensor 800 does not suffer from the disadvantages suffered byabsolute sensor 700 with respect to the requirements forgel layer 760. In other words, withgauge pressure sensor 800, it is possible to measure exhaust pressure as the applied pressure, without adding expensive gels to protect the sensitive electronics in thelayer 830. - Thus, according to the present invention, a method is described for controlling exhaust gas recirculation using an absolute sensor to measure intake manifold pressure (which does not require expensive gels since intake manifold pressure gases are at a lower temperature and have less contaminants than exhaust pressure gases) and a gauge pressure sensor to measure a pressure of recycled exhaust gases (which can be at a higher temperature and have various contaminants). In other words,
gauge pressure sensor 800 can be manufactured cheaply and provide useful measurements of recycled exhaust gases. Thus, according to the present invention, a reduced cost system can be provided. - Although several examples of the invention have been described herein, there are numerous other examples that could also be described. For example, the invention can also be used with various types of emission control devices such as so-called lean burn catalysts. Further, the improved barometric pressure estimate can be used in other engine control systems. For example, the improved barometric pressure estimate can be used in scheduling engine actuators and desired engine operating points. In particular, the improved barometric pressure estimate can be used in determining a desired EGR flow, or EGR valve, set-point. Then, the measured, or estimated EGR flow value can be used in a feedback control scheme so that the actual EGR flow, or valve position, approaches the set-point value. Further, the improved barometric pressure estimate can be used in determining a ignition timing set-point. In other words, desired ignition timing can be varied based on the determined barometric pressure.
Claims (13)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US09/681,860 US6659095B2 (en) | 2001-06-19 | 2001-06-19 | Diagnosis system for upstream gauge sensor, downstream absolute pressure sensor |
DE10225104A DE10225104A1 (en) | 2001-06-19 | 2002-06-05 | Method and arrangement for controlling an exhaust gas recirculation engine using two pressure sensors |
GB0213307A GB2379032A (en) | 2001-06-19 | 2002-06-11 | Vehicle exhaust gas recirculating system with detection of pressure sensor de terioration. |
Applications Claiming Priority (1)
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US09/681,860 US6659095B2 (en) | 2001-06-19 | 2001-06-19 | Diagnosis system for upstream gauge sensor, downstream absolute pressure sensor |
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US20020189599A1 true US20020189599A1 (en) | 2002-12-19 |
US6659095B2 US6659095B2 (en) | 2003-12-09 |
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US09/681,860 Expired - Lifetime US6659095B2 (en) | 2001-06-19 | 2001-06-19 | Diagnosis system for upstream gauge sensor, downstream absolute pressure sensor |
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US (1) | US6659095B2 (en) |
DE (1) | DE10225104A1 (en) |
GB (1) | GB2379032A (en) |
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Also Published As
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US6659095B2 (en) | 2003-12-09 |
GB0213307D0 (en) | 2002-07-24 |
GB2379032A (en) | 2003-02-26 |
DE10225104A1 (en) | 2003-01-23 |
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